Ford F-250 Heavy Duty 1997, F-350 1997, F-Super Duty 1997 Service Guide

General Information

Table of Contents

Maintenance Schedule and Record ............ 3

General Maintenance Information ............ 3

Normal Schedule ............................................ 8

Severe Duty Schedule ................................. 31

What Maintenance Schedule Do You

Follow? .............................................................. 6

Owner Maintenance Checks ...................... 62

Maintenance Schedule and Record

The required Scheduled Maintenance Services listed in this booklet are considered essential to the proper operation, safety and performance of your Ford Motor Company vehicle. We recommend that you also perform the Owner Maintenance Checks listed. These services are matters of day-to-day care that are also important to the proper operation of your vehicle. The recommended lubricants, fluids and service parts conforming to Ford Specifications are available from your dealer.

This booklet gives you a place to record the services that are performed on your vehicle so that you can keep a record of when parts should be checked or replaced. Give your Maintenance Schedule booklet to the dealer service manager.

Maintenance: An investment

An investment which will pay dividends in the form of improved reliability, durability, and resale value.

To assure the durability of your vehicle and its emission control systems, it is necessary that scheduled maintenance be performed at the designated intervals.

Ford strongly recommends the use of genuine Ford replacement parts. If other than Ford or Motorcraft parts or Ford authorized remanufactured parts are used for maintenance replacements or for the service of components affecting emission control, such non-Ford parts should be equivalent to genuine Ford Motor Company parts in performance and durability. It is the owner’s responsibility to determine the equivalency of such parts. Please consult your warranty booklet for complete warranty information.

No Cost PCV Valve Replacement

THE PCV VALVE IS A CRITICAL EMISSION COMPONENT. YOUR DEALER WILL REPLACE THE VALVE AT NO COST AT 60,000 MILES/96,000 KILOMETERS (EXCEPT CANADA AND CALIFORNIA VEHICLES).

FOR VEHICLES WITH 7.5L EFI ENGINES, YOUR DEALER WILL REPLACE THE PCV VALVE AT NO COST AT 60,000 MILES/96,000 KILOMETERS (EXCEPT CANADA VEHICLES).

Wheel Lug Nuts

Wheel lug nuts must be retightened to proper torque specifications at 500 miles/800 km of new vehicle operation (100 miles/160 km for vehicles equipped for snowplowing). Proper torque specifications are provided in your Owner Guide. Also retighten to proper torque specification at 500 miles/800 km after (1) any wheel change or (2) any other time the wheel lug nuts have been loosened.

PRE-DELIVERY CHECK

Pre-Delivery Service Inspection Completed

❑

What Maintenance Schedule Do You Follow?

Normal

Schedule

Follow the Normal Schedule for most normal everyday driving conditions.

Severe Duty

Schedule

Follow the Severe Duty Schedule if your driving habits FREQUENTLY include one or more of the following conditions:

Towing a trailer or carrying a heavy load.

❑

Operating in severe dust conditions.

❑

Extensive idling, such as police, taxi or

❑

door-to-door delivery service. Snowplowing

❑

Off-Road operation

❑

Short trips of less than 10 miles (16 km)

❑

when outside temperatures remain below 0˚F (-18˚C).

NOTE: Idling the engine for extended periods

will accumulate more hours of use on your vehicle than is actually indicated by the mileage odometer. Consequently, the odometer reading can be often misleading when determining the right time to change your engine oil and filter.

NOTE: If you are using your Ford vehicle in a

manner which allows it to remain stationary while the engine is running for long periods (door to door delivery, taxi, police, power/utility company trucks, or similar duty), then Ford recommends you increase the frequency of oil and filter changes to an interval equivalent to 200 ENGINE HOURS of use. Since most vehicles are not equipped with hourmeters, it may be necessary for you to approximate your idle time and plan oil/filter changes accordingly.

Normal Schedule

NOTE: Items for Emission Control Service are shown in this type and style.

For items marked with number in parentheses such as (1), see footnote at end of this section.

NOTE: Rear axle lube quantities must be

replaced every 100,000 miles (160,000 km) or if the axle has been submerged in water. Otherwise, the lube should not be checked or changed unless a leak is suspected or repair required.

Regular

Maintenance

Intervals

for the Normal

Schedule

5,000 MILES (8,000 Kilometers)

Change engine oil and replace oil filter.

❑

Rotate tires and adjust air pressure. (1)(2)

❑

Check and lubricate clutch release lever (7.5L

❑

and 7.3L DIT Diesel). Check clutch reservoir fluid level.

❑

Inspect and lubricate automatic transmission

❑

shift linkage.

8 Normal Schedule

Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

10,000 MILES (16,000 Kilometers)

Change engine oil and replace oil filter.

❑

15,000 MILES (24,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

For 7.3L DIT Diesel Engines, add 8-10 ounces of

❑

FW-15 to the engine coolant every 15,000 miles (24,000 km).

Rotate tires and adjust air pressure. (1)(2)

❑

Normal Schedule 9

Check clutch reservoir fluid level.

❑

Lubricate transfer case shift lever pivot bolt

❑

and control rod connecting pins (4x4). Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect disc brake system, lubricate caliper

❑

slide rails. Inspect drum brake systems, hoses and lines.

❑

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

Inspect parking brake fluid level (F-Super

❑

Duty). Replace fuel filter every 15,000 miles

❑

(24,000 km) or when the filter restriction lamp is illuminated (7.3L DIT Diesel only).

Check spring U-bolt torque (F-Super Duty).

❑

Change fuel filter (Recommended but not

❑

required for California Certified Vehicles).

10 Normal Schedule

20,000 MILES (32,000 Kilometers)

Change engine oil and replace oil filter.

❑

Check and lubricate clutch release lever (7.5L

❑

and 7.3L DIT Diesel).

25,000 MILES (40,000 Kilometers)

Change engine oil and replace oil filter.

❑

Rotate tires and adjust air pressure. (1)(2)

❑

Check clutch reservoir fluid level.

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

Normal Schedule 11

30,000 MILES (48,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

For 7.3L DIT Diesel Engines, add 8-10 ounces of

❑

FW-15 to the engine coolant every 15,000 miles (24,000 km).

Replace air cleaner filter every 30,000 miles

❑

(48,000 km) or 30 months. If operating in dusty conditions, consult your dealer and/or follow severe duty maintenance schedule.

Replace the air cleaner filter when the restriction

❑

gauge is in the red zone (7.3L DIT Diesel only). Replace crankcase emission air filter. If operating

❑

in dusty conditions consult your dealer and/or follow severe duty maintenance schedule. (7.5L only.)

Lubricate transfer case shift lever pivot bolt

❑

and control rod connecting pins (4x4). Inspect disc brake system, lubricate caliper

❑

slide rails. Inspect drum brake systems, hoses and lines.

❑

Inspect and lubricate front wheel bearings.

❑

Inspect parking brake system for damage and

❑

operation. Inspect parking brake fluid level (F-Super

❑

Duty). Lubricate throttle kickdown or TV lever ball

❑

studs.

12 Normal Schedule

Lubricate front axle R.H. axle shaft slip yoke

❑

(4x4). Inspect and lubricate spindle needle bearings

❑

(4x4). Inspect and lubricate hub locks (4x4).

❑

Check spring U-bolt torque (F-Super Duty).

❑

Replace fuel filter every 15,000 miles

❑

(24,000 km) or when the filter restriction lamp is illuminated (7.3L DIT Diesel only).

Change fuel filter (Recommended but not

❑

required for California Certified Vehicles).

35,000 MILES (56,000 Kilometers)

Change engine oil and replace oil filter.

❑

Rotate tires and adjust air pressure. (1)(2)

❑

Check and lubricate clutch release lever (7.5L

❑

and 7.3L DIT Diesel). Check clutch reservoir fluid level.

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

Normal Schedule 13

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

40,000 MILES (64,000 Kilometers)

Change engine oil and replace oil filter.

❑

45,000 MILES (72,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

For 7.3L DIT Diesel Engines, add 8-10 ounces of

❑

FW-15 to the engine coolant every 15,000 miles (24,000 km).

Rotate tires and adjust air pressure. (1)(2)

❑

Check clutch reservoir fluid level.

❑

Lubricate transfer case shift lever pivot bolt

❑

and control rod connecting pins (4x4). Inspect and lubricate automatic transmission

❑

shift linkage.

14 Normal Schedule

Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Change fuel filter (Recommended but not

❑

required for California Certified Vehicles). Replace fuel filter every 15,000 miles

❑

(24,000 km) or when the filter restriction lamp is illuminated (7.3L DIT Diesel only).

Inspect disc brake system, lubricate caliper

❑

slide rails. Inspect drum brake systems, hoses and lines.

❑

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

Inspect parking brake fluid level (F-Super

❑

Duty). Check spring U-bolt torque (F-Super Duty).

❑

Normal Schedule 15

50,000 MILES (80,000 Kilometers)

Change engine oil and replace oil filter.

❑

Change engine coolant initially at 50,000 miles

❑

(80,000 km) or 48 months. Thereafter, change engine coolant every 30,000 miles (48,000 km) or 36 months (Gasoline engines only).

For 7.3L DIT Diesel, add four (4) pints of FW-15

❑

each time engine coolant is changed.

Check and lubricate clutch release lever (7.5L

❑

and 7.3L DIT Diesel).

55,000 MILES (88,000 Kilometers)

Change engine oil and replace oil filter.

❑

Rotate tires and adjust air pressure. (1)(2)

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

16 Normal Schedule

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

60,000 MILES (96,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

Replace spark plugs (Gasoline engines only).

❑

Replace air cleaner filter every 30,000 miles

❑

(48,000 km) or 30 months. If operating in dusty conditions, consult your dealer and/or follow severe duty maintenance schedule.

Replace the air cleaner filter when the restriction

❑

gauge is in the red zone (7.3L DIT Diesel only). Replace crankcase emission air filter. If operating

❑

in dusty conditions consult your dealer and/or follow severe duty maintenance schedule. (7.5L only.)

Replace PCV valve. (3)

❑

Check thermactor hoses and clamps.

❑

(Recommended, not required.)

Lubricate transfer case shift lever pivot bolt

❑

and control rod connecting pins (4x4).

Normal Schedule 17

Replace fuel filter every 15,000 miles

❑

(24,000 km) or when the filter restriction lamp is illuminated (7.3L DIT Diesel only).

Change fuel filter (Recommended but not

❑

required for California Certified Vehicles). Inspect disc brake system, lubricate caliper

❑

slide rails. Inspect drum brake systems, hoses and lines.

❑

Inspect and lubricate front wheel bearings.

❑

Inspect parking brake system for damage and

❑

operation. Inspect parking brake fluid level (F-Super

❑

Duty). Lubricate throttle kickdown or TV lever ball

❑

studs. Inspect and lubricate spindle needle bearings

❑

(4x4). Inspect and lubricate hub locks (4x4).

❑

Change transfer case oil (4x4).

❑

Lubricate front axle R.H. axle shaft slip yoke

❑

(4x4). Change manual transmission oil.

❑

Check spring U-bolt torque (F-Super Duty).

❑

18 Normal Schedule

65,000 MILES (104,000 Kilometers)

Change engine oil and replace oil filter.

❑

For 7.3L DIT Diesel Engines, add 8-10 ounces of

❑

FW-15 to the engine coolant every 15,000 miles (24,000 km).

Rotate tires and adjust air pressure. (1)(2)

❑

Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

Inspect and lubricate automatic transmission

❑

shift linkage. Check clutch reservoir fluid level.

❑

Check and lubricate clutch release lever (7.5L

❑

and 7.3L DIT Diesel).

Normal Schedule 19

70,000 MILES (112,000 Kilometers)

Change engine oil and replace oil filter.

❑

75,000 MILES (120,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

Rotate tires and adjust air pressure. (1)(2)

❑

Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

Inspect disc brake system, lubricate caliper

❑

slide rails. Inspect drum brake systems, hoses and lines.

❑

Change fuel filter (Recommended but not

❑

required for California Certified Vehicles).

20 Normal Schedule

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